One piece molded pallet stringer

ABSTRACT

A one piece molded pallet stringer is integrally formed as one single, unitary, integral and monolithic piece of material and includes a first, front block section or portion, a second, rear block section or portion, a third, center block section or portion, a bottom deck board section or portion and a top deck board section or portion.

This application claims the benefit of the filing date of provisional application Ser. No. 62/947,843, which was filed on Dec. 13, 2019. Provisional patent application Ser. No. 62/947,843 is herein incorporated by reference.

FIELD

This disclosure pertains to the construction of a one piece molded pallet stringer. More specifically, this disclosure pertains to the construction of a one piece molded pallet stringer, and a pallet that is comprised of one piece molded stringers. Each stringer is comprised of a first, front block section or portion, a second, rear block section or portion, a third, center block section or portion, a bottom deck board section or portion and a top deck board section or portion that are all integrally formed as one single, unitary, integral and monolithic piece of material, for example a plastic material.

The elimination of wood in the construction of the one piece molded stringer makes a pallet that is comprised of one piece molded stringers lightweight, reduces the cost of manufacturing the pallet, and reduces the amount of wasted or discarded wood in constructing pallets with the one piece molded stringers.

BACKGROUND

The wood pallet is by far the most commonly used pallet in the United States, FIG. 1 is a representation of the prior art, standard North American pallet 10 or a Grocery Manufacturers Association (GMA) style pallet. The pallet 10 represented in FIG. 1 is constructed of three wood stringers 12. The lengths of the stringers 12 are parallel and spatially positioned across the width of the pallet 10. The stringers are provided with notches 14 in their bottom edges. The notches 14 are dimensioned to accommodate blades of a forklift. The forklift blades are inserted through the notches 14 to enable lifting of the pallet 10 by the forklift. The blades of the forklift can also be inserted between the spatially arranged stringers 12.

A plurality of top deck boards 16 are attached to the top surfaces of the stringers 12 and extend across the stringers. The top deck boards 16 are also constructed of wood. In the pallet 10 represented in FIG. 1, there are five top deck boards 16.

The pallet 10 is also constructed with a plurality of bottom deck boards 18. The bottom deck boards 18 are also constructed of wood. As represented in FIG. 1, the bottom deck boards 18 are attached to the bottom surfaces of the stringers 12 and extend across the stringers.

The wood used in the construction of the pallet 10 makes the pallet heavy, expensive, bulky and wood intensive. The wood is also susceptible to mold and mildew. Widespread use of wood pallets has resulted in environmental problems and waste disposal problems.

SUMMARY

The one piece molded pallet stringer of this disclosure eliminates wood needed to construct a pallet and thereby lowers the cost of constructing a new pallet and lowers the weight of the pallet. The stringer is constructed entirely of plastic. The stringer could be constructed of recycled plastic material, and is itself recyclable which further lowers the cost of a pallet constructed of the stringers. The stringer could be constructed as a solid, single piece, or could be constructed with internal hollow cavities that further reduce the weight of the stringer.

The one piece molded pallet stringer has a configuration comprised of several different sections or portions of the stringer. Although the stringer configuration has several different sections or portions, the several different sections or portions are all formed together in the unitary, one piece molded construction of the stringer.

The one piece molded plastic stringer consists of sections or portions that include a first, front block; a second, rear block; a third, center block; a bottom deck board; and a top deck board.

The first, front block has a general rectangular, cubic configuration with a top and an opposite bottom plane surface.

The second, rear deck block has a general rectangular, cubic configuration with a top and an opposite bottom plane surface.

The third, center block has a general rectangular, cubic configuration with a top and an opposite bottom.

The bottom deck board has the general configuration of a plank. The bottom deck board has a length between a first, front end of the bottom deck board having a front end surface of the bottom deck board and a second, rear end of the bottom deck board having a rear end surface of the bottom deck board.

The top deck board has a general configuration of a plank. The top deck board has a length between a first, front end of the top deck board having a front end surface of the top deck board and a second, rear end of the top deck board having a rear end surface of the top deck board.

The first, front end of the bottom deck board is joined with the first, front block with the bottom surface of the first, front block being exposed and with the front end surface of the bottom deck board projecting from the bottom surface of the first, front block at a perpendicular orientation to the bottom surface of the first, front block.

The second, rear end of the bottom deck board is joined with the second, rear block with the bottom surface of the second, rear block being exposed and with the rear end surface of the bottom deck board projecting from the bottom surface of the second, rear block at a perpendicular orientation to the bottom surface of the second, rear block.

The first, front end of the top deck board is joined with the first, front block.

The second, rear end of the top deck board is joined with the second, rear block,

Further objects and features of the one piece molded pallet stringer are set forth in the following detailed description of the stringer and in the drawing figures.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a representation of a top perspective view of a wood pallet.

FIG. 2 is a representation of a perspective view of the one piece molded pallet stringer.

FIG. 3 is a representation of a perspective view of a pallet constructed of the one piece molded pallet stringers.

DETAILED DESCRIPTION

FIG. 2 is a representation of a perspective view of the one piece molded pallet stringer 20 of this disclosure. In this disclosure, the stringer 20 is constructed as one piece, or one single, integral and monolithic piece of material. The stringer 20 is constructed by molding the stringer 20 as one piece, for example by compression molding, by injection molding or another equivalent molding process. The stringer 20 could be constructed of a plastic material, for example a recycled plastic material, or a composite material, or another equivalent type of material.

The stringer 20 is comprised of a first block or a front block 22 section or portion. As represented in FIG. 2, the first block 22 has a rectangular, cubic configuration with a length dimension along opposite sides of the first block 22 represented from right to left in FIG. 2 as being approximately twice a height dimension of the first block 22. The first block 22 also has a width dimension between the opposition sides of the first block 22. As represented in FIG. 2, the stringer 20 is shown in an upside down orientation with the first block 22 having a top or top plane 24 and an opposite bottom surface 26.

The stringer 20 also has a second block or a rear block 32 section or portion. The second block 32 also has a rectangular, cubic configuration and has dimensions substantially the same as those of the first block 22. With the stringer 20 shown oriented upside down in the representation of FIG. 2, the second block 32 has a top or top plane 34 and an opposite bottom surface 36.

The stringer 20 is also comprised of a third, center block 42 section or portion. The third block 42 also has a rectangular, cubic configuration with a length dimension along opposite sides of the third block 42 that is approximately half the length dimension of the first block 22 and the second block 32. The third block 42 also has a height dimension between a top 44 and a bottom 46 of the center block 42 and a width dimension between the opposite sides of the third block 42 that are substantially the same as the height dimension and width dimension of the first block 22 and the second block 32. With the stringer 20 represented as being oriented upside down in FIG. 2, the third block 42 has a top or top plane 44 and an opposite bottom or bottom plane 46.

The stringer 20 is also comprised of a bottom deck board 52 section or portion. The bottom deck board 52 has a configuration of a plank with a length that extends between a first end or front end 54 of the bottom deck board 52 having a front end surface 56, and an opposite second end or rear end 58 of the bottom deck board 52 having a rear end surface 62. The bottom deck board 52 is joined as one piece to the first block 22 adjacent the bottom surface 26 of the first block 22, is joined as one piece to the second block 32 adjacent bottom surface 36 of the second block 32 and is joined as one piece to the bottom 46 of the third block 42. The length dimension of the bottom deck board 52 positions the first end 54 of the bottom deck board 52 joined to a portion of the first block 22 adjacent the bottom surface 26 of the first block 22. The bottom surface 26 of the first block 22 adjacent the first end 54 of the bottom deck board 52 is exposed and the front end surface 56 of the bottom deck board 52 projects away from the bottom surface 26 of the first block 22 at a perpendicular orientation to the bottom surface 26. The length dimension of the bottom deck board 52 also positions the second end 56 of the bottom deck board 52 joined to a portion of the second block 32 adjacent the bottom surface 36 of the second block 32. The bottom surface 36 of the second block 32 adjacent the second end 58 of the bottom deck board 52 is exposed and the rear end surface 62 of the bottom deck board 52 projects away from the bottom surface 36 of the second block 32 at a perpendicular orientation to the bottom surface 36.

The stringer 20 is also comprised of a top deck board 72 section or portion. The top deck board 72 has a configuration of a plank with a length dimension between a first end or front end 74 of the top deck board 72 having a front end surface 76, and a second end or rear end 78 of the top deck board 72 having a rear end surface 82. As represented in FIG. 2, the length dimension of the top deck board 72 positions the first end 74 of the top deck board 72 joined as one piece to and entirely across the top 24 of the first block 22, joined as one piece to and entirely across the top 34 of the second block 32 and joined as one piece to and entirely across the top 44 of the third block 42.

As stated earlier, the first block 22, the second block 32, the third block 42, the bottom deck board 52 and the top deck board 72 that comprise the one piece molded stringer 20 are all constructed as one single, integral and monolithic piece of material.

FIG. 3 is a representation of a perspective view of assembling a pallet using the one piece molded stringer 20. The pallet 92 represented in FIG. 3 is constructed of three stringers 20, 20′, 20″, with each of the stringers having a same construction of the stringer described above in referring to FIG. 2. Because the constructions of each of the three stringers 20, 20′, 20″ is the same, the stringer constructions will not again be described in describing the construction of the pallet 92 represented in FIG. 3.

As represented in FIG. 3, the three stringers 20, 20′, 20″ are positioned in parallel orientations with a spacing between the stringers. The first blocks 22, 22′, 22″ of the respective stringers 20, 20′, 20″ are aligned and the second blocks 32, 32′, 32″ of the respective stringers 20, 20′, 20″ are aligned. These relative positions of the stringers 20, 20′, 20″ can be maintained by placing the stringers 20, 20′, 20″ in a jig configured to hold the stringers 20, 20′, 20″ in their relative positions represented in FIG. 3.

With the three stringers 20, 20′, 20″ in their relative positions represented in FIG. 3, a first, front bottom slat 94 is accurately positioned in notches defined by and is secured to the bottom surfaces 26, 26′, 26″ of the respective first blocks 22, 22′, 22″ of the respective three stringers 20, 20′, 20″ and the respective front end surfaces 56, 56′, 56″, of the bottom deck boards 52, 52′, 52″. The first, front bottom slat 94 can be secured to the bottom surfaces 16, 16′, 16″ of the respective first blocks 12, 12′, 12″ of the respective stringers 20, 20′, 20″ using fasteners such as nails, or other equivalent types of fasteners, or by using adhesives.

A second, rear bottom slat 96 is accurately positioned in notches defined by and is secured to the bottom surfaces 36, 36′, 36″ of the respective second blocks 32, 32′, 32″ of the respective three stringers 20, 20′, 20″ and the respective rear end surfaces 62, 62′, 62″ of the bottom deck boards 52, 52′, 52″. The second, rear bottom slat 96 can be secured to the bottom surfaces 36, 36′, 36″ of the respective second blocks 32, 32′, 32″ of the respective stringers 20, 20′, 20″ by fasteners such as nails, or other equivalent types of fasteners, or by adhesives. This completes the construction of the bottom of the pallet 92 represented in FIG. 3. The pallet 92 can then be flipped over to an upright orientation to secure top slats across the top deck boards 72, 72′, 72″ of the respective stringers 20, 20′, 20″ to complete the construction of the pallet 92.

The one piece molded construction of the stringer 20 enables shipping large quantities of the stringers 20 to pallet assembly locations where pallets can be constructed in the manner described above with reference to FIG. 3. The ability to ship the one piece molded stringers 20 to pallet assembly locations as opposed to shipping assembled pallets improves the economy of scale in the pallet industry when shipping pallets long distances. The one piece molded stringers 20 can be shipped very cost efficiently. The assembly of a pallet from the one piece molded stringers 20 eliminates fasteners needed for pallet assembly. For example, a pallet assembled using three of the stringers 20 can eliminate 24 nails. Assembling pallets using the stringer 20 also eliminates the need for stringer assembly machines. Assembling a pallet from the one piece molded stringers 20 would take one person approximately 30 seconds to assemble the pallet, where a conventional pallet takes 1-2 minutes for one person to assemble.

As various modifications could be made in the construction of the one piece molded pallet stringer and its method of operation herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present disclosure should not be limited by any of the above described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents. 

1. A stringer that is a one piece molded pallet stringer, the stringer comprising: a front block, the front block having a top and an opposite bottom surface; a rear block, the rear block having a top and an opposite bottom surface; a bottom deck board having a length between a first, front end of the bottom deck board and a second, rear end of the bottom deck board, the bottom deck board length extends between a front end surface of the bottom deck board and an opposite rear end surface of the bottom deck board, the front end surface and the rear end surface being opposite end surfaces at opposite ends of the length of the bottom deck board; the first, front end of the bottom deck board being joined with the front block with the bottom surface of the front block being exposed and with the front end surface of the bottom deck board projecting away from the bottom surface of the front block; and, the second, rear end of the bottom deck board being joined with the rear block with the bottom surface of the rear block being exposed and with the rear end surface of the bottom deck board projecting away from the bottom surface of the rear block.
 2. The stringer of claim 1, further comprising: a top deck board having a length between a first, front end of the top deck board and a second, rear end of the top deck board; the first, front end of the top deck board being joined with the top of the front block; and, the second, rear end of the top deck board being joined with the top of the rear block.
 3. The stringer of claim 2, further comprising: a center block; the bottom deck board being joined with the center block; and, the top deck board being joined with the center block with the bottom deck board and the top deck board being on opposite sides of the center block.
 4. The stringer of claim 3, further comprising: a first opening through the stringer between the front block and the center block and between the bottom deck board and the top deck board; and, a second opening through the stringer between the rear block and the center block and between the bottom deck board and the top deck board.
 5. The stringer of claim 3, further comprising: the front block, the rear block, the center block, the bottom deck board and the top deck board together being a single, unitary piece of material.
 6. The stringer of claim 2, further comprising: a front, bottom slat; the front, bottom slat being separate from the stringer, the front, bottom slat being secured to the bottom surface of the front block; and, a rear, bottom slat, the rear, bottom slat being separate from the stringer, the rear, bottom slat being secured to the bottom surface of the rear block.
 7. The stringer of claim 2, further comprising: the stringer being a first stringer; a second stringer, the second stringer having a front block, the front block of the second stringer having a top and an opposite bottom surface; the second stringer having a rear block, the rear block of the second stringer having a top and an opposite bottom surface; the bottom deck board being a first bottom deck board; a second bottom deck board, the second bottom deck board having a length between a first, front end of the second bottom deck board and a second, rear end of the second bottom deck board; the first, front end of the second bottom deck board being joined with the front block of the second stringer with the bottom surface of the front block of the second stringer being exposed; and, the second, rear end of the second bottom deck board being joined with the second rear block with the bottom surface of the second rear block being exposed.
 8. The stringer of claim 7, further comprising: a third stringer; and, the first stringer, the second stringer and the third stringer each having a same construction.
 9. A stringer that is a one piece molded pallet stringer, the stringer comprising: a front block, the front block having a rectangular, cubic configuration with a top and an opposite bottom plane surface; a rear block, the rear block having a general rectangular, cubic configuration with a top and an opposite bottom plane surface; a bottom deck board, the bottom deck board having a configuration of a plank, the bottom deck board having a length between a first, front end of the bottom deck board having a front end surface of the bottom deck board and a second, rear end of the bottom deck board having a rear end surface of the bottom deck board, the bottom deck board length extends between the front end surface of the bottom deck board and the rear end surface of the bottom deck board, the front end surface of the bottom deck board and the rear end surface of the bottom deck board are at opposite end surfaces at opposite ends of the length of the bottom deck board; the first, front end of the bottom deck board being joined with the front block with the bottom plane surface of the front block being exposed and with the front end surface of the bottom deck board projecting from the bottom plane surface of the front block at a perpendicular orientation to the bottom plane surface of the front block; and, the second, rear end of the bottom deck board being joined with the rear block with the bottom plane surface of the rear block being exposed and with the rear end surface of the bottom deck board projecting from the bottom plane surface of the rear block at a perpendicular orientation to the bottom plane surface of the rear block.
 10. The stringer of claim 9, further comprising: a center block, the center block having a rectangular, cubic configuration; and, the bottom deck board being joined with the center block.
 11. The stringer of claim 10, further comprising: a top deck board, the top deck board having a configuration of a plank, the top deck board having a length between a front end of the top deck board having a front end surface of the top deck board and a rear end of the top deck board having a rear end surface of the top deck board; the front end of the top deck board being joined with the front block; and, the rear end of the top deck board being joined with the rear block.
 12. The stringer of claim 11, further comprising: the bottom deck board being joined with the center block; the top deck board being joined with the center block; a first opening through the stringer between the front block and the center block and between the bottom deck board and the top deck board; and, a second opening through the stringer between the rear block and the center block and between the bottom deck board and the top deck board.
 13. The stringer of claim 11, further comprising: the front block, the rear block, the center block, the bottom deck board and the top deck board together being a single, unitary piece of material.
 14. The stringer of claim 11, further comprising: a front, bottom slat, the front, bottom slat being separate from the stringer, the front, bottom slat being secured to the bottom surface of the front block; and, a rear, bottom slat, the rear, bottom slat being separate from the stringer, the rear, bottom slat being secured to the bottom surface of the rear block.
 15. The stringer of claim 14, further comprising: the stringer being a first stringer; a second stringer; the second stringer having a front block, the front block of the second stringer having a rectangular, cubic configuration, the front block of the second stringer having a top and an opposite bottom surface; the second stringer having a rear block, the rear block of the second stringer having a rectangular, cubic configuration, the rear block of the second stringer having a top and an opposite bottom surface; the front, bottom slat being secured to the bottom surface of the front block of the second stringer; and, the rear, bottom slat being secured to the bottom surface of the rear block of the second stringer.
 16. The stringer of claim 15, further comprising: a third stringer; and, the first stringer, the second stringer and the third stringer each having a same construction.
 17. A stringer that is a one piece molded pallet stringer, the stringer consisting of: a front block, the front block having a top and an opposite bottom surface; a rear block, the rear block having a top and an opposite bottom surface; a center block, the center block having a top and an opposite bottom; a bottom deck board having a length between a first, front end of the bottom deck board and a second, rear end of the bottom deck board, the bottom deck board length extends between a front end surface of the bottom deck board and an opposite rear end surface of the bottom deck board, the front end surface of the bottom deck board and the rear end surface of the bottom deck board being opposite end surfaces at opposite ends of the length of the bottom deck board; the first, front end of the bottom deck board being joined with the front block with the bottom surface of the front block being exposed and with the front end surface of the bottom deck board projecting away from the bottom surface of the front block; the second, rear end of the bottom deck board being joined with the rear block with the bottom surface of the rear block being exposed and with the rear end surface of the bottom deck board projecting away from the bottom surface of the rear block; the bottom deck board being joined with the center block; a top deck board having a length between a first, front end of the top deck board and a second, rear end of the top deck board; the first, front end of the top deck board being joined with the top of the front block; the second, rear end of the top deck board being joined with the top of the rear block; and, the top deck board being joined with the center block with the bottom deck board and top deck board being on opposite sides of the center block.
 18. The stringer of claim 17, consisting of: a first opening through the stringer between the front block and the center block and between the bottom deck board and the top deck board; and, a second opening through the stringer between the rear block and the center block and between the bottom deck board and the top deck board.
 19. The stringer of claim 18, further comprising: the front block, the rear block, the center block, the bottom deck board and the top deck board together being a single, unitary piece of material.
 20. The stringer of claim 19, further comprising: a front, bottom slat, the front, bottom slat being separate from the stringer, the front, bottom slat being secured to the bottom surface of the front block; and, a rear, bottom slat, the rear, bottom slat being separate from the stringer, the rear, bottom slat being secured to the bottom surface of the rear block. 